Order
Removing the front wheel and brake disc
I Disconnect:
1 Speedometer cable 1
II Remove:
2 Front brake caliper 1
3 Wheel axle nut 1
4 Wheel axle 1
5 Front wheel assembly 1
6 Speedometer gear 1
7 Collar 2
8 Brake disc 1
Remove the parts in the order listed.
Securely support the scooter so there is no danger of it falling over.
NOTE:
Place the scooter on a suitable stand so that the front wheel is elevated.
Refer to "INSTALLING THE FRONT WHEEL"
For installation, reverse the removal procedure.
Q'ty
Job/Part Remarks
WARNING
EAS00513
CHASSIS
FRONT WHEEL AND BRAKE DISC
FRONT WHEEL AND BRAKE DISC
FWD
1
2
7 3 4
5 7
8 6
T.R 35 Nm (3,5 m.kg)
T.R 23 Nm (2,3 m.kg)
LT
FRONT WHEEL AND BRAKE DISC
Order
Disassembling the front wheel
I Remove:
1 Oil seal 1
2 Bearing 2
3 Collar 1
Remove the parts in the order listed.
Refer to "DISASSEMBLING/ASSEM-BLING THE FRONT WHEEL" section.
For assembly, reverse the disassembly procedure.
Q'ty
Job/Part Remarks
EAS00518
FRONT WHEEL
FWD
1 3
2 2
FRONT WHEEL AND BRAKE DISC
EAS00520
REMOVING THE FRONT WHEEL
1.Stand the motorcycle on a level surface.
Securely support the motorcycle so that there is no danger of it falling over.
NOTE:
Place the motorcycle on a suitable stand so that the front wheel is elevated.
2.Disconnect:
• Speedometer cable 3.Remove:
• Front brake caliper 4.Loosen:
• Axle nut 5.Remove:
• Axle nut
• Front wheel axle
• Front wheel assembly
• Speedometer gear
• Collar
• Front wheel
• Brake disc NOTE:
Never depress the brake lever when the wheel is off the scooter. Otherwise the brake pads will be forced out.
Handle the wheel with care not to damage the brake disc. If the brake disc is damaged, replace it.
EAS00523
DISASSEMBLING THE FRONT WHEEL 1.Remove:
• Oil seal
• Wheel bearings CAUTION:
WARNING
6-4
FRONT WHEEL AND BRAKE DISC
a.Clean the outside of the front wheel hub.
b.Remove the oil seal with a flat-head screwdriver.
NOTE:
To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface.
EAS00525
CHECKING THE FRONT WHEEL 1.Check:
• Wheel axle
Roll the wheel axle on a flat surface.
Bends → Replace.
Do not attempt to straighten a bent wheel axle.
2.Check:
• Tire
• Front wheel
Damage/wear → Replace.
Refer to "CHECKING THE TIRES" and
"CHECKING THE WHEELS" in chapter 3.
3.Measure:
• Radial wheel runout
• Lateral wheel runout
Over the specified limits → Replace.
Radial wheel runout limit 1.0 mm
Lateral wheel runout limit 1.0 mm
WARNING
c. Remove the wheel bearings with a general bearing puller .
2.Remove:
• Collar
;;;
FRONT WHEEL AND BRAKE DISC
4.Check:
• Wheel bearings
Front wheel turns roughly or is loose → Replace the wheel bearings.
• Oil seals
Damage/wear → Replace.
5.Replace:
• Wheel bearings
• Oil seals
a.Clean the outside of the front wheel hub.
b.Remove the oil seals with a flat-head screwdriver.
NOTE:
To prevent damaging the wheel, place a rag between the screwdriver and the wheel surface.
c. Remove the wheel bearings with a general bearing puller .
CAUTION:
@
@
d.Install the new wheel bearings and oil seals in the reverse order of disassembly.
Do not contact the wheel bearing inner race
or balls . Contact should be made only with the outer race .
NOTE:
Use a socket that matches the diameter of the wheel bearing outer race and oil seal.
6.Inspect:
• Collar
Wear/Damage → Replace collar and oil seal as set.
FRONT WHEEL AND BRAKE DISC
EAS00528
CHECKING THE BRAKE DISC 1.Check:
• Brake disc
Damage/galling → Replace.
2.Measure:
• Brake disc deflection
Out of specification → Inspect wheel runout.
If wheel runout is in good condition, correct the brake disc deflection or replace the brake disc.
Brake disc deflection limit (maximum)
0.2 mm
a.Place the scooter on a suitable stand so that the front wheel is elevated.
b.Before measuring the front brake disc deflection, turn the handlebar to the left or right to ensure that the front wheel is stationary.
c. Remove the brake caliper.
d.Hold the dial gauge at a right angle against the brake disc surface.
e.Measure the deflection 2 ~ 3 mm below the edge of the brake disc.
347002 347001
3.Measure:
• Brake disc thickness
Measure the brake disc thickness at a few different locations.
Out of specification → Replace.
Brake disc thickness limit (minimum)
3.2 mm 4.Adjust:
• Brake disc deflection a.Remove the brake disc.
b.Rotate the brake disc by one bolt hole.
c. Install the brake disc.
NOTE:
Tighten the brake disc bolts in stages and in a crisscross pattern.
FRONT WHEEL AND BRAKE DISC
Brake disc bolt 23 Nm (2.3 m • kg)
d.Measure the brake disc deflection.
e.If out of specification, repeat the adjustment steps until the brake disc deflection is within specification.
f. If the brake disc deflection cannot be brought within specification, replace the brake disc.
EAS00535
CHECKING THE SPEEDOMETER GEAR UNIT
1.Check:
• Speedometer clutch
Bends/damage/wear → Replace.
2.Check:
• Speedometer drive gear
• Speedometer driven gear
Damage/wear → Replace the speedometer gear unit.
340004(a)
EAS00539
ASSEMBLING THE FRONT WHEEL 1.Install:
• Wheel bearings
• Oil seals
a.Install the new wheel bearings and oil seals in the reverse order of disassembly.
Do not contact the wheel bearing inner race
or balls . Contact should be made only with the outer race .
NOTE:
Use a socket that matches the diameter of the wheel bearing outer race and oil seal.
CAUTION:
T.R 23 Nm (2,3 m.kg)
LT
EAS00542*
INSTALLING THE FRONT WHEEL 1.Lubricate:
• Wheel axle
• Wheel bearings
• Oil seal lips
• Speedometer drive gear
• Speedometer driven gear Recommended lubricant
Lithium soap base grease 2.Install:
• Brake disc
Brake disc bolt 23 Nm (2.3 m • kg) NOTE:
Tighten the brake disc bolts in stages and in a crisscross pattern.
3.Install:
• Speedometer gear unit NOTE:
Make sure the speedometer gear unit and the wheel hub are installed with the two projections meshed into the two slots respectively.
4.Install:
• Front wheel
Be sure to assemble the front wheel as shown.
Difference between A and B < 3 mm
FRONT WHEEL AND BRAKE DISC
WARNING A B
T.R 23 Nm (2,3 m.kg)
LT
EAS00548
ADJUSTING THE FRONT WHEEL STATIC BALANCE
NOTE:
• After replacing the tire, wheel or both, the front wheel static balance should be adjusted.
• Adjust the front wheel static balance with the brake disc installed.
1.Remove:
• Balancing weight(s) 2.Find:
• Front wheel’s heavy spot NOTE:
Place the front wheel on a suitable balancing stand.
a.Spin the front wheel.
b.When the front wheel stops, put an “X1” mark at the bottom of the wheel.
c. Turn the front wheel 90° so that the “X1” mark is positioned as shown.
d.Release the front wheel.
e.When the wheel stops, put an “X2” mark at the bottom of the wheel.
f. Repeat steps (c) through (f) several times until all the marks come to rest at the same spot.
g.The spot where all the marks come to rest is the front wheel’s heavy spot “X”.
FRONT WHEEL AND BRAKE DISC
5.Tighten:
• Wheel axle
• Brake caliper bolts Wheel axle
35 Nm (3.5 m • kg) Brake caliper bolt
23 Nm (2.3 m • kg)
Make sure the brake hose is routed properly.
Before tightening the axle nut, stroke the front fork several times to check for proper fork operation.
WARNING
CAUTION:
X1
X2 X1
3.Adjust:
• Front wheel static balance
a.Install a balancing weight onto the rim exactly opposite the heavy spot “X”.
NOTE:
Start with the lightest weight.
b.Turn the front wheel 90° so that the heavy spot is positioned as shown.
c. If the heavy spot does not stay in that position, install a heavier weight.
d.Repeat steps (b) and (c) until the front wheel is balanced.
FRONT WHEEL AND BRAKE DISC
4.Check:
• Front wheel static balance
a.Turn the front wheel and make sure it stays at each position shown.
b.If the front wheel does not remain stationary at all of the positions, rebalance it.
X
X
X
X
X
X